Packaging machine

ABSTRACT

A tool assembly ( 20 ) for folding a carrier (H) comprising a first pair of fingers ( 24   a ) for gripping a blank (B) for forming the carrier (H), a second pair of fingers ( 24   b ) for gripping the blank (B), the first pair of fingers ( 24   a ) being pivotally coupled with respect to one another, and the second pair of fingers ( 24   b ) being pivotally coupled with respect to one another, the first and second pairs of fingers being coupled to an actuator for movement between a receiving position and a gripping position wherein the fingers are operable to engage a blank (B) in the receiving position and fold said blank (B) when disposed in the gripping position, at least one pair of fingers being rotationally mounted to a body ( 42 ) of a tool head ( 22 ) and coupled to a drive mechanism ( 32   a,    32   b ) for rotation with respect to the body ( 42 ), such that a first portion of the blank (B) is foldable with respect to a second portion.

FIELD OF THE INVENTION

The present invention relates to a packaging machine and a method of applying a carton to form a package more specifically, but not exclusively, to a packaging machine for forming and applying a carrying handle structure to an article; to a tool assembly used in the packaging machine; and to a method of constructing a package.

BACKGROUND OF THE INVENTION

In the field of packaging it is often required to provide consumers with a package comprising multiple primary product containers. Such multi-packs are desirable for shipping and distribution and for display of promotional information. For cost and environmental considerations, such cartons or carriers need to be formed from as little material as possible and cause as little wastage in the materials from which they are formed as possible. Another consideration is the strength of the packaging and its suitability for being used to carry and transport groups of articles.

In PCT/US2013/20762 filed to the present applicant, which has been filed on the same day as the present application and which is hereby incorporated herein by reference, an attachable carrying handle is disclosed. The carrying handle is attachable to an article group by engagement of a tooth on a hook of the handle with an engaging member provided by the article group. The article group may be an array of frangibly connected flanged cups, such as yoghurt cups. Additionally, a top cover optionally providing an advertising panel is disclosed, which is folded about an article group and attached thereto by the carrying handle.

It is desirable to automate or provide an apparatus to increase the speed and/or accuracy of manual application of a carrying handle to an article group. Furthermore, where the grouped articles are stacked in tiers, co-ordinated manipulation of the articles to be grouped is beneficial to increase the rate at which completed packages are formed.

The present invention seeks to provide an improvement in the field of packaging, more specifically but not exclusively by providing an automated packaging apparatus for and a method of automatically forming and attaching a carrying handle to one or more tiers of grouped articles, and to an apparatus and method for improving the speed and accuracy with which a carrying handle is attached to one or more tiers of grouped articles manually or semi-manually.

SUMMARY OF INVENTION

According to a first aspect of the present invention there is provided a tool assembly for folding a blank to form a carrying handle, the tool assembly comprising a first pair of fingers for gripping a blank, and a second pair of fingers for gripping the blank. The fingers of the first pair of fingers are pivotally coupled with respect to one another, and the fingers of the second pair of fingers are pivotally coupled with respect to one another. The fingers of each of the first and second pairs of fingers are coupled to an actuator for movement between a receiving position and a gripping position, wherein the fingers of the first and second pairs are configured to engage a blank in the receiving position, and configured to fold said blank when disposed in the gripping position. At least one of the first and second pairs of fingers are rotationally mounted to a body of a tool head, and coupled to a drive mechanism for rotation with respect to the body, such that the tool assembly is configured to grip first and second portions of the blank and to fold the first portion of the blank with respect to the second portion of the blank.

Preferably, the tool head is slidably mounted to a carriage for linear movement with respect to the carriage. Preferably, the carriage is mounted to a conveyor. Optionally, the conveyor is endless. The term endless is used here to describe the conveyor itself being a closed loop and does not necessarily refer to the path of the conveyor, which may be linear as illustrated or in other embodiments, circular or oval.

According to a second aspect of the present invention there is provided a method of packaging groups of articles comprising: forming a carrying handle from a blank; folding a first portion of the blank about a longitudinally extending fold line; holding the first portion in said folded condition whilst folding said first portion about a transverse fold line to be substantially perpendicular to a second portion; and inserting said first portion into an aperture or void disposed between four adjacent articles forming part of a group of articles. The first portion comprises a first engaging edge for locking with a second engaging edge of the group of articles; the first engaging edge engages with said second engaging edge by at least partially unfolding the first portion about the longitudinal fold line.

Preferably, the method comprises: folding a third portion of the blank about a longitudinally extending fold line; holding the third portion in said folded condition whilst folding said third portion about a transverse fold line to be substantially perpendicular to the second portion; inserting said third portion into a second aperture or void defined by four adjacent articles in the group of articles; and unfolding the third portion about said longitudinally extending fold line 50 so as to engage an engaging edge of the third portion with an engaging edge of the group of articles, thereby locking the third portion within the second aperture or void.

Preferably, the entire blank is folded about a longitudinally extending fold line and the second portion is unfolded into a substantially flat condition when the first and/or third portions are folded to be perpendicular to the second portion.

According to a third aspect of the present invention, there is provided a packaging machine for packaging a group of articles comprising:

-   -   (i) a conveyor for providing a group of articles;     -   (ii) a conveyor for providing a blank for forming a carrying         handle;     -   (i) a tool assembly comprising a pair of fingers for folding a         first portion of the blank about a longitudinally extending fold         line;     -   (ii) the fingers being pivotally mounted to a tool head of the         tool assembly for folding the first portion of the blank to be         substantially perpendicular to a second portion of the blank;     -   (iii) wherein the tool head is slideably mounted to a carriage         for insertion of the first portion into an aperture or void in         the group of articles.

Preferably, the fingers grip the blank and hold the first portion of the blank in a folded condition when in a closed position.

Alternatively, the fingers hold the first portion of the blank in a folded condition whilst folding the first portion about a transverse fold line, so as to be substantially perpendicular to the second portion.

Alternatively, the tool assembly comprises a second pair of fingers mounted to the tool head for folding a third portion of the blank about a longitudinally extending fold line. The fingers are pivotally mounted to the tool head for folding the first portion of the blank to be substantially perpendicular to the second portion, whilst the third portion is held in a folded condition about the longitudinally extending fold line.

Preferably, the packaging machine comprises a lug or mandrel mounted on a conveyor for engaging with the blank for facilitating folding of the blank about the longitudinal fold line.

Preferably, the packaging machine comprises at least one guide for insertion between a pair of articles in the group of articles. The guide aligns the first portion or third portion of the blank during insertion into the group of articles and maintains the first or third portion in a folded condition.

According to a third aspect of the present invention, there is provided a packaging machine for packaging a group of articles comprising: a guide for insertion between a pair of articles in the group of articles, the guide comprising a recess for receiving and maintaining a first portion of a carrying handle in a folded condition during insertion of the first portion of the carrying handle into the group of articles.

Within the scope of this application it is envisaged that the various aspects, embodiments, examples, features and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, may be taken independently or in any combination thereof. For example, features described in connection with one embodiment are applicable to all embodiments unless there is incompatibility of features.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the invention will now be described with reference to the accompanying drawings, in which:

FIG. 1 is a schematic illustration of a perspective view from above of a packaging machine according to a first embodiment of the invention;

FIG. 2 is a perspective view from above of the packaging machine of FIG. 1 at a slightly later point in time;

FIG. 3 is yet a further perspective view from above of the packaging machine of FIG. 1 at an even later point in time;

FIG. 4 is an enlarged perspective view from above of a portion of the packaging machine of FIG. 1;

FIG. 5 is another enlarged perspective view from above of a portion of the packaging machine of FIG. 1 at a later point in time;

FIG. 6 is a schematic illustration of a perspective view from above of a tool head of the packaging machine of FIG. 1;

FIG. 7 is a perspective view from above of the tool head of FIG. 6 preparing to engage a blank;

FIG. 8 is a perspective view from above of the tool head of FIG. 6 engaging and folding a blank;

FIG. 9 is a perspective view from above of the tool head of FIG. 6 further folding a blank;

FIG. 10 is a perspective view from above of the tool head of FIG. 6 completing the folding of the blank into a carrying handle;

FIG. 11 is a perspective view from above of the tool head of FIG. 6 preparing to release the carrying handle;

FIG. 12 is a perspective view from above of the tool head of FIG. 6 releasing the carrying handle;

FIG. 13 is a perspective view from above of the tool head of FIG. 6 preparing to install the carrying handle into a grouped array of articles;

FIG. 14 is a perspective view from above of a packaging machine according to a second embodiment of the invention forming a package;

FIG. 15 is a perspective view from above of the packaging machine of FIG. 14;

FIG. 16 is a perspective view from above of a packaging machine according to a third embodiment of the invention;

FIG. 17 is a perspective view from above of a packaging apparatus according to a fourth embodiment of the invention; and

FIGS. 18-22B are perspective views from above of the packaging apparatus of FIG. 17.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE PRESENT INVENTION

Detailed descriptions of specific embodiments of the packaging machines and methods are disclosed herein. It will be understood that the disclosed embodiments are merely examples of the way in which certain aspects of the invention can be implemented, and do not represent an exhaustive list of all of the ways the invention may be embodied. As used herein, the word “exemplary” is used expansively to refer to embodiments that serve as illustrations, specimens, models, or patterns. Indeed, it will be understood that the packaging machines and methods described herein may be embodied in various and alternative forms. The figures are not necessarily to scale and some features may be exaggerated or minimised to show details of particular components. Well-known components, materials or methods are not necessarily described in great detail in order to avoid obscuring the present disclosure. Any specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the invention.

Referring to FIG. 1, there is shown a schematic perspective view of a packaging machine 10 capable of accepting an input of primary products such as, but not limited to, pots, yoghurt pots, bottles and cans, hereinafter referred to as articles C. In the preferred embodiment, the pots comprise a flange, preferably disposed about an upper portion thereof, and the articles C are coupled together into groups G by frangible connections between adjacent flanges of the articles C.

A blank B is formed from a sheet of suitable substrate. It is to be understood that, as used herein, the term “suitable substrate” includes all manner of foldable sheet material such as paperboard, corrugated board, cardboard, plastic, combinations thereof, and the like. It should be recognized that one or other numbers of blanks may be employed, for example, to provide the carrying handle structure described in more detail below.

Optionally, the blank B may be any suitable blank B for forming an attachable carrying handle that may optionally be configured to group together one or more tiers of articles C (such as frangibly connected, flanged cups) and to provide a carrying handle for the one or more tiers of articles. A variety of such suitable blanks B are described in PCT/US2013/20762 to the present applicant. Additionally, in PCT/US2013/20762, the use of a top cover or supplementary panel is described. The present application is directed to the formation of such or similar carrying handles from blanks B; optionally, to the formation of a top cover; optionally, to the formation of a package comprising one or more tiers of articles C and a carrying handle formed from a blank B; and, optionally, to the formation of a package comprising one or more tiers of articles C, a carrying handle formed from a blank B, and a top cover.

Turning now to FIGS. 1 to 5, FIG. 1 illustrates a packaging machine 10 for application of a blank B to a group of articles C. In the preferred embodiment, the articles C are coupled to one another; however, in alternative embodiments, a second blank (not shown) may be provided to couple the articles C together. In the illustrated example, the groups G of articles C comprise two tiers of articles C, each tier of articles C being arranged in a 2×3 array of connected cups C. In those embodiments where the articles C are not coupled to one another by flanges, the blank B or one or more additional blanks may be provided to couple the articles C in each tier together.

Each tier of articles C comprises at least one aperture A for receiving a portion of a carrying handle H formed from the blank B. In the illustrated embodiment, the tiers of articles C comprise two apertures A, each aperture A configured to receive a respective hook portion of the carrying handle formed from the blank B.

Articles C are provided on a first conveyor 12 and conveyed in a downstream direction (as indicated by direction arrow D1), towards a first overhead conveyor 18 which forms part of an erecting station and an application station of the packaging machine 10.

The first overhead conveyor 18 is configured to convey tool assemblies 20 about a working reach and a return reach, in the direction indicated by direction arrow D2. The tool assemblies 20 each comprise a tool head 22 comprising fingers 24 that are described in more detail below.

Optionally, slightly upstream of the sub-assembly shown in FIG. 1, a hopper for blanks B (not shown) is provided to store a supply of blanks B ready for being fed into the presently illustrated sub-assembly. A feeder mechanism (not shown), is provided to remove the blanks B from the hopper one at a time and place them sequentially upon a second conveyor (not shown in FIG. 1), preferably at a pre-determined pitch, such that a steady and sequential supply of blanks B are provided. The second conveyor is provided to convey the supplied blanks B to the upstream end of the first overhead conveyor 18. At the first overhead conveyor 18, each blank B is engaged by fingers 24 of the tool head 22. (An optional sub-assembly providing a hopper 150 for storing blanks B, a feeder 152 for transferring blanks B, and a blank conveyor 113 is shown and described in respect of the second embodiment. In such an exemplary sub-assembly, the blank conveyor 113 partially overlaps with a second overhead conveyor 114. Such an exemplary sub-assembly is suitable for use also in respect of the first described embodiment, for ensuring that a continuous and regularly spaced supply of blanks B is provided to the packaging machine arrangement 10 for manipulating and installing handles into an article group G).

A second overhead conveyor 14 is provided, optionally substantially above and over the first conveyor 12. The second overhead conveyor 14 optionally comprises a pair of chains or belts spaced apart, so as to be disposed substantially at opposing ends of the blanks B as they are conveyed through the working reach of the first overhead conveyor 18. The spaced apart belts may rotate as illustrated by direction arrow D4 in FIG. 5. Each chain or belt comprises lugs 30, (best illustrated in FIG. 4). Lugs 30 optionally support the opposing ends of each blank B as a supply of blanks through part of the working reach of the first overhead conveyor 18. Lugs 30 are arranged to have an inverted V-shape to facilitate folding of the blank B. In other envisaged embodiments other suitable shapes for facilitating folding of the blanks B may be used.

A third overhead conveyor 16 is provided, and is disposed within the boundary of, or at least proximate to, the second overhead conveyor 14. The third overhead conveyor 16 optionally comprises a pair of chains or belts disposed between, or at least proximate to, the chains or belts of the second overhead conveyor 14 which are moved in a direction D5 preferably in synchrony with the first and second conveyors 18, 14 (see FIG. 4). The second overhead conveyor 14 is preferably disposed in overlapping relationship with the third overhead conveyor 16. The third overhead conveyor 16 provides a series of shaped guides or lugs 28 for assisting the folding of the blank B (see FIG. 4).

The belts or chains of the third overhead conveyor 16 are spaced apart so as to be substantially disposed at opposing ends of the blank B. The third overhead conveyor 16 comprises a lug or flight bar 28 extending between the pair of chains or belts, as is best illustrated in FIG. 4.

The packaging machine 10 comprises a fourth conveyor 26. Fourth conveyor 26 comprises a pair of belts or chains spaced apart and arranged so as to be at opposing ends of the article groups G as they are conveyed by the first conveyor 12. The spaced apart belts rotate in opposite directions, optionally; the front most belt 26 in FIG. 2 rotates in a clock-wise manner as illustrated by D3, whereas the rearmost belt rotates in an anti-clockwise manner. The fourth conveyor 26 comprises lugs (not shown), which lugs engage with the groups G of articles C as they are conveyed. These lugs and the fourth overhead conveyor 26 maintain the article groups in alignment, whilst a carrying handle H formed by folding the blank B is applied to them.

FIGS. 1 to 5 illustrate a sequence of folding operations that are repeatedly performed by the packaging machine 10. The folding sequence of a blank B into a carrying handle H, and the subsequent installation of that carrying handle H, is performed by a single tool head 20, 20 a, 20 b, 20 c, 20 d or 20 e of the first overhead conveyor 18, operating in conjunction with the second and third overhead conveyors 14, 16. The manipulation of the blank B, and installation of the carrying handle H, will be described in respect of a series of sequential blanks B as they are conveyed through a working reach of the first overhead conveyor 18, second overhead conveyor 14 and third overhead conveyor 16. As shown in FIG. 1, a blank B is brought into alignment with the lugs 30 of the second overhead conveyor 14 at the upstream end thereof (optionally by a hopper and feeder mechanism upstream of the present sub-assembly). A tool head 20 is brought into vertical registry with the blank B, as is best shown in FIG. 3.

A preceding tool head 20 a is shown in FIG. 3, illustrating that as the tool head 20 a, a blank B and lugs 30 move downstream together, the tool head 20 a engages with the blank B (as shown in FIGS. 1, 2, 3 and 7).

Fingers 24 of the tool head 20 a engage with the blank B, as is best shown by tool head 20 a of FIG. 2 (also see fingers 24 a, 24 b in enlarged view in FIGS. 6, to 13). Fingers 24, 24 a, 24 b are pinched together to fold the blank B about a longitudinal fold line, such that blank B folds about the lugs 30 and lugs 28 as they are conveyed and manipulated by tool heads 20 a and 20 b, see FIG. 3 and FIGS. 1, 2, 4 and 5 respectively. In other words, the v-shaped fingers 24, 24 a, 24 b are each mechanically closed together, sandwiching the blank therebetween and folding it along the longitudinal fold line.

The third overhead conveyor 16 is positioned and aligned relative to the first overhead conveyor 18 such that as the folding of the blank B about its longitudinal fold line(s) is nearly completed, the lug 28 (also referred to as a shaped guide) is then disengaged from the blank B. The lug 28 is then conveyed through the return reach of the third overhead conveyor 16 and returned to the upstream end of third overhead conveyor 16 to engage with a successive blank B. The tool head (tool head 20 c in FIG. 4) is then able to further complete the folding of the blank B. Lugs 30 from the second overhead conveyor 14 are still in contact with the blank B to provide stability and/or guidance to each of its ends. The blank B is conveyed to the end of the second overhead conveyor 14, at which point the pair of guiding lugs 30 are disengaged from the blank B.

Blanks B are conveyed at a pitch that is equal to (or otherwise suitably timed with) that of the groups G of articles C on the first conveyor 12. Once the blanks B leave the second overhead conveyor 14, the fingers 24 are rotated approximately through 90° towards each other so as to form two downwardly pointing legs, or hook portions, of the handle H being formed from the blank B. In this way, the blank B is formed into an approximately inverted U-shape. Tool head 20 d (see FIG. 4) comprises an extensible head 22 that is mounted to the tool head 20 d such that it is configured to move approximately vertically downwardly and upwardly (optionally relative to the first conveyor 12). In the preferred, but optional, embodiment, this is achieved with a piston which may be hydraulically, pneumatically or electrically operated for example.

The folded blank B forms a carrying handle H which is lowered into engagement with an article group G by downward movement of the head 22. Each leg of the pair of downwardly pointing legs (also referred to as hook portions) of the carrying handle H is inserted into a respective one of a pair of apertures in the article group G (see FIGS. 4 and 5). The fingers 24 preferably maintain the downwardly pointing legs in a folded condition, during their insertion into the apertures A as shown in FIG. 5.

In FIGS. 6 to 8, enlarged schematic views of one of the tool heads, 20 d, is shown. The exemplary tool head 20 d, illustrated schematically, comprises a moveable head 22 and fingers 24 (which optionally comprise two sets of fingers 24 a, 24 b) as already described. Referring to FIG. 6, the tool head 20 d optionally comprises a body 42 to which is mounted a pair of drive motors 32 a, 32 b for control of each of a respective set of fingers 24 a, 24 b. Each set of fingers 24 a, 24 b is mounted upon an arm 38 a, 38 b which is pivotally mounted to the body 42. A pulley wheel 36 is coupled to each arm 38 a, 38 b by a shaft which passes through the body 42. Preferably, a bearing is provided for facilitating rotational movement of the shaft within the body 42.

The pulley wheel 36 is coupled to a second pulley wheel coupled to the drive motor 32 a, 32 b by a belt 34 or chain. In alternative embodiments, a gear system may replace the pulley wheels 36 and belt 34.

Fingers 24 a, 24 b are each formed as a scissor grip: a pair of first class levers is pivotally mounted to each of their respective arms 38 a, 38 b, about pivot points 44 b. A piston 40 a, 40 b is mounted to each arm 38 a, 38 b and is coupled to a first (effort) end 46 a, 46 b of the levers (see FIGS. 9 and 10). The piston 40 a, 40 b is coupled to an actuator which separates the first ends 46 a, 46 b of each lever with respect to one another. In doing so, opposing (load) ends 24 a, 24 b of the levers are also separated. The levers are spring loaded, or resiliently biased, so as to be closed in an unbiased condition. In this way, extension of the piston 40 a, 40 b opens the two fingers 24 a, 24 b, and retraction of the piston 40 a, 40 b closes the fingers 24 a, 24 b.

FIGS. 7 to 13 further illustrate the optional operation of the tool head 20 d folding the blank B into a carrying handle H. In FIG. 7, tool head 20 d is brought into vertical registry with a blank B; the fingers 24 a, 24 b are in an open condition, the pistons 40 a, 40 b being fully extended and a rod 41 b that guides the reciprocating movement of the piston 40 b can be seen.

FIG. 8 illustrates the tool head 20 d gripping the blank B. The blank B has been folded in half along a longitudinal axis thereof. The fingers 24 a, 24 b are pinched together as indicated by direction arrows D7, D7′. The pistons 40 a, 40 b have been fully retracted, as indicated by direction arrow D6. The fingers 24 a, 24 b grip the blank B. The fingers 24 a are spaced apart from the fingers 24 b such that each pair of fingers 24 a, 24 b engages with a portion of the blank B which will form one of the downwardly pointing legs (hook portions) of the carrying handle H.

FIGS. 9 to 11 illustrate the further folding of the blank B to form a carrying handle H. The arms 38 a, 38 b are rotated in opposite directions, as indicated by direction arrows D10 and D11. This is achieved by rotating the drive motor 32 a, 32 b such that the outermost portion of each belt 34 is moved downward as indicated by direction arrow D8. This, in turn, rotates the pulley wheel 36 anticlockwise (see D9, visible in FIG. 9). The other pulley wheel 36 is rotated clockwise. The legs (hook portions) of the blank B are thereby folded towards each other, as indicated by direction arrows D12 and D13 in FIG. 9. In FIGS. 10 and 11, the arms 38 a, 38 b are shown in their fully outwardly rotated position. The degree to which the arms move may be adjusted dependent upon the type of blank B being manipulated. In the present embodiment, the blank B is preferably folded such that the leg (hook portions) are folded approximately 90° relative to a top handle portion of the carrying handle H. However, where the apparatus of the present invention is applied to the manipulation and/or installation of other styles, types and structures, the arms 38 a, 38 b may be rotated to a lesser or greater degree. For example, in a carrying handle arrangement where the legs are disposed at, for example, 95° relative to the top handle portion, the arms 38 a, 38 b will be rotated to a lesser degree than is shown in FIGS. 10 and 11.

FIG. 10 illustrates the carrying handle H in an erected state. The arms 38 a, 38 b have each been rotated through about 90°. Optionally, the tool head 20 d may carry out a horizontal adjustment of the position of the blank B/carrying handle H in the direction D15, D15′ (as shown in FIG. 11). This adjustment may be required to ensure alignment of the carrying handle H with an article group G to which the carrying handle H is to be applied.

At this stage the carrying handle H is engaged with a group G of articles C. The tool head 20 d then disengages the carrying handle H by extending the piston 40 a, 40 b as indicated by direction arrow D14 as shown in FIG. 11. Referring now to FIG. 12, the tool head 20 d then rotates the arms 38 a, 38 b such that arm 38 a rotates clockwise, as indicated by direction arrow D17, and arm 38 b rotates anticlockwise as indicated by direction arrow D19. Arm 38 a is rotated by drive motor 32 a, which moves belt 34 such that the outermost portion moves upwardly, as indicated by direction arrow D16 and, in turn, pulley wheel 36 rotates clockwise as indicated by direction arrow D18.

The tool head 20 d is configured, as described above, to execute the timely downward relative movement of the folded carrying handle H for installing the carrying handle H into the article group G. This may optionally be achieved by the entire tool head 20 d following a cam path as it is conveyed by the first overhead conveyor 18, so that its path moves downwardly and then returns to its starting position, or, alternatively and as is shown here, a head portion 22 of the tool head 20 d is moved, optionally by a piston 40 a, 40 b as described. The downward movement may occur at the same time, or in overlapping time, as the disengagement of the fingers 24 a, 24 b and their rotation (see FIGS. 12 and 13) is synchronized and timed such that the fingers 24 a, 24 b are disengaged before the tool head 20 d has moved downwardly, so close to the article group G to complete the installation of the carrying handle H that there is not sufficient space for the fingers 24 a, 24 b to open and rotate back into their starting position.

The tool head 20 d may optionally, but preferably, be configured to push downwardly on the carrying handle H to ensure that it is fully inserted into the group G of articles C. This may be achieved by the downward path of the head portion 22 being configured to just meet or marginally overlap the upper surface of the article group G. Once the installation is completed, the head portion 22 moves upwardly to take up its starting position ready for the manipulation and installation of another blank B.

Referring now to FIGS. 14 to 22, there are shown alternative embodiments of the present invention. In the second and third illustrated embodiments, like numerals have, where possible, been used to denote like parts, albeit with the addition of the prefix “100” or “200” and so on to indicate that these features belong to the second embodiment. The alternative embodiments share many common features with the first embodiment, and therefore only the differences from the embodiment illustrated in FIGS. 1 to 13 will be described in any greater detail.

FIGS. 14 and 15 illustrate a packaging machine according to a second embodiment of the invention, for manipulating and installing a blank B for forming a carrying handle H into a group of articles G. In this embodiment, the groups G of articles C are conveyed on a first conveyor 112. The groups G of articles C are disposed on the first conveyor 112 such that one of the apertures A is disposed upstream of the other of the apertures A. As such, the article groups G are rotated 90° compared to the orientation of the article groups G of the first embodiment shown in FIGS. 1 to 5.

A hopper 150 is provided to store blanks B, and a feeder 152 is provided to transfer the blanks B from the hopper 150 to a first blank conveyor 113. The first blank conveyor 113 partially overlaps with the second overhead conveyor 114.

Supplementary heads 129 are optionally mounted on tool assemblies (also referred to as tool heads) 120, 120 a, 120 b, 120 c, 120 d, 120 e that are conveyed in direction D102 by the first overhead conveyor 118. The supplementary heads 129 are provided for conducting rotational movement of head portions 122 and the fingers 124, such that the blanks B, once picked up from the second overhead conveyor 116 can be rotated through 90° (or other appropriate angle to ensure alignment of the blank B with the apertures of the article group G). The blanks B are placed upon the first blank conveyor 113 such that a longitudinal axis of the blank B is disposed perpendicularly to the direction of travel, as indicated by direction arrow D101. In order to be inserted into the article groups G, the carrying handle H formed by folding the blank B must be rotated such that the longitudinal axis is parallel with the direction of travel D101. This is achieved by rotating the tool head 122 with respect to the tool assembly 120. This is optionally achieved by the provision of the supplementary head 129.

The article groups G are maintained in position by a fourth conveyor 126 which, in this embodiment, comprises lugs 127 moving in direction D103. Lugs 127 are arranged in pairs, such that a pair of lugs 127 engages with each respective article group G. A leading lug 127 of the pair of lugs 127 may engage a leading edge of the article group G, and a trailing lug 127 may engage between a pair of adjacent articles C in the group G. In alternative embodiments other engagement arrangements are envisaged. For example, the lugs 127 may engage different locations of the article group G, or additional lugs 127 may be provided to engage at supplementary locations. The provision of lugs 127 assists in maintaining the stability of the article group during carrying handle installation.

Packaging machine 110, optionally, additionally comprises a fifth conveyor 151, comprising lugs or flight bars 153 disposed over the article groups G rotating in direction D105. Fifth conveyor 151 is disposed downstream of the carrying handle application station defined in part by the fourth conveyor 126 and is provided to optionally apply a downward force to the handle H and/or article group G and handle H to ensure that the carrying handle H is properly installed within the article group G. The carrying handle H preferably comprises one or more teeth on each leg portion and the downward pressure applied by the tool head 120 and/or optional fifth conveyor 151 may ensure that the one or more teeth are properly engaged with an underside edge of one or more flanges of the group of articles G.

A sixth conveyor 156 comprising a pair of belts or chains disposed on opposing sides of the article groups G, is provided in partially overlapping relationship with fifth conveyor 151. Sixth conveyor 156 comprises lugs 158 which engage the article groups G. Optionally, sixth conveyor 156 is provided to convey the grouped articles G with carrying handles H installed therein out of the manipulation and installation sub-assembly and optionally into a further processing station (optionally such as that described in the third embodiment below). The conveyor 156 rotates in direction D104.

FIG. 16 illustrates a further exemplary embodiment, optionally an adaptation of the packaging machine 110 of the second embodiment of FIGS. 14 and 15, wherein the packaging machine 210 has been adapted such that it can apply an additional or alternative blank/carton B to the article groups G.

The packaging machine 210 optionally comprises a second blank conveyor 260 for conveying second blanks T. Optionally, this second blank conveyor 260 may also take over from a first conveyor 212 and may convey both the second blanks T and the article groups G together. As such, the second blank conveyor 260 is disposed proximate to, optionally above, and in partial overlapping relationship with the first conveyor 212 which conveys the article groups G. Preferably, the second blank conveyor 260 is operated in time or synchrony, with the first conveyor 212.

The completion of the formation of the second blanks T that are applied to the article groups G by the feeder 250 may be carried out at a second blank application/completion station 290 that is defined in part by the fifth and sixth conveyors 256. Guide rails 254 may be provided for folding side panels 274 of the second blanks T about the article groups G.

According to one optional arrangement, the packaging machine 210 is configured to apply a top cover T to a group of articles G. The top cover T is mechanically attached or affixed to the article group G by the attachment of a carrying handle H to the article group G, through apertures provided in the top cover T and through apertures present in the article group G. In this way, the top cover T becomes sandwiched between the carrying handle H and an uppermost tier of articles C.

As can be seen in FIG. 16, top cover blanks T are supplied and placed on top of the article groups G by the feeder mechanism 250 (which may comprise rotating suction cups, as is known) such that a primary panel of the top cover blank T is placed on top of the uppermost tier of articles C in the group G. The first overhead conveyor 218 and tool heads 220 then attend to the manipulation, folding and installation of a carrying handle H as described above. The carrying handle H may be installed through apertures in both the article group G and correspondingly sized and arranged apertures (not shown) in the top cover T. Following the carrying handle installation, the article groups G having an unfolded top cover blank T affixed thereto, (referred to as a work product W in FIG. 16) are supplied to second blank application/completion station 290. Whereat, static guide rails 254 may be provided to cause the downward folding of one or more side panels 274.

In a further optional arrangement, the top cover blank T additionally comprises bottom flaps for forming a wrapped around carton structure having a composite bottom-wall, the second blank application/completion station 290 of the packaging machine 210 may be provided with further guide rails (not shown) which may fold the optional bottom flaps of the blank T about the base of the article groups G. To complete the package, the bottom end flaps may be secured together either adhesively or mechanically using a locking mechanism or other suitable means.

FIGS. 17 to 22B illustrate a manual, semi-automatic or automatic apparatus for packaging a group of articles, according to a third embodiment.

Packaging machine 310 comprises a platform 312. In the illustrated embodiment, the platform 312 is stationary; however, it is envisaged that the platform may be formed from a conveyor belt or similar; the article conveyor may pause at a loading station.

The packaging machine 310 comprises a pair of guides 374 a, 374 b slidably mounted within the platform 312. In other embodiments, the guides 374 a, 374 b may be mounted on an overhead conveyor comprising a pair of chains or belts disposed on opposing sides of an article conveyor. A plurality of guides may be mounted on the belts or chains of the overhead conveyor, and may be moved synchronously with the article conveyor.

The platform 312 comprises a pair of posts 370 (see FIG. 22A). Posts 370 are each star shaped and are shaped and sized in a complementary manner to a void present between four adjacent articles in a first tier L1 of a tier of connected articles C. The posts 370 are received in a pair of adjacent voids in the lower tier L1 of articles C as shown in FIG. 18. Two posts 370 are optionally provided to accommodate article groups G disposed in a 2×3 array, having two voids beneath two apertures A, each between a group of four adjoined and adjacent articles C. In other envisaged arrangements the size, shape, spacing, configuration and/or number of posts 370 may be differed to suit the requirements of an article group being (optionally) stacked, grouped and having a carrying handle installed.

Guides 374 a, 374 b are provided relative to the posts 370 and mounted on moveable posts 378 a, 378 b disposed within slots 376 a, such that they can assist in the proper alignment, and assist in maintaining the folded configuration, of a carrying handle H as it is installed into an article group G. The guides 374 a, 374 b are optionally height adjustable, or height moveable, so that they can be disposed over and above a first lower tier L1 of articles (see FIG. 19). Further, the guides 374 a, 374 b are moveable, by a sliding movement as indicated by direction arrows D301, D301′ (again see FIG. 19). A second tier L2 of articles C is positioned over the guides 374 a, 374 b such that the guides 374 a, 374 b can be disposed between a pair of endmost articles of adjacent rows at each end of the group of articles forming the second or upper tier L2.

The guides 374 a, 374 b each comprise a V-shaped recess or pair of divergently arranged fingers extending from an inner end of the guides. Each V-shaped recess is arranged to receive a respective one of the downwardly facing legs of the carrying handle H. The guides 374 a, 374 b are otherwise planar or thin in construct so that they can be positioned between articles C of a group of articles G.

The V-shaped recess guides the legs of the carrying handle towards a respective aperture A in the first, lower, tier L1 and prevents the legs from unfolding as the legs are inserted into the article group G in direction D303 (see FIG. 20) and direction D304 (as shown in FIG. 21). The guides 374 a, 374 b are retracted (see direction arrows D305′ and D301) as shown in FIG. 22B from the package P such that the package can be removed from the platform 312.

Optionally, the use of one or more of guides 374 a, 374 b may assist in the installation of the carrying handle H into one or more tiers of articles. Where only a single tier is used, the tier may rest on posts 370 (see FIG. 22A) on the platform 312, and one or both guides 374 a, 374 b may be pushed into the article group between the end most articles of the group, so that the or each guide 374 a, 374 b is correctly disposed to receive and guide the legs or hook portions of the carrying handle H. Optionally, the guides 374 a, 374 b may be moved manually, and optional push-pull handles 372 may be provided to assist that. Further, optionally, the movement of the internal guides 374 a, 374 b may be automated or semi-automated. For example, with reference to FIGS. 18, 19, 20, 21 and/or 22B, a mechanism may be provided for automating the relative inward and outward movement of the guides 374 a, 374 b. A pinion gear 380 may be driven by a drive means, for example an electric motor (not shown). Rotation of the pinion gear 380 by the drive means is configured to cause the linear movement of each of two parallel racks 382 (only one rack 382 is visible in the Figures) simultaneously. The rack and pinion 382, 380 arrangement is configured such that both guide rails 374 a, 374 b will be moved outwardly or inwardly together. One guide rail is attached to one of the racks whilst the other guide rail is attached to the other of the racks. Clockwise (forward) rotation of the pinion gear 380 (direction D302 in FIG. 19) may cause each rack, and thereby each guide 374 a, 374 b, to move inwardly, whereas anti-clockwise (reverse) rotation of the pinion gear 380 may cause each guide 374 a, 374 b to move outwardly. The drive means may be operable by a foot pedal, for example, in semi-automatic operation.

Further optionally, it is envisaged that one or more guides 374 a, 374 b may be used in a fully-automated arrangement. For example, a series of “V”-shaped (or other suitably shaped) guides 374 a, 374 b may be mounted by an arm onto one of two oppositely positioned conveyors (such as an endless belt or chain), disposed either side of the first conveyor 12. Each arm may follow a cam path to cause the guide 374 a on one conveyor, and another optional guide 374 b on the other opposite conveyor, to move into and intersect an uppermost tier of grouped articles G and then be withdrawn therefrom after installation of the carrying handle through voids in the grouped articles G.

It can be appreciated that various changes may be made within the scope of the present invention, for example, the size and shape of the blank for forming a carrying handle may be varied. Upon reading the foregoing, it will be understood that a carrying handle having a single leg (or hook portion) may be installed by means of a similar process. In such or other arrangements of the packaging machine, only one set of fingers 24 a may be provided. The number, position, configuration of the conveyors, their format and drive means may be varied from that shown and described, providing that the components used are suitable for organizing and supporting a supply of one or more blanks, a supply of articles or stacked articles and for manipulating and installing the folded blanks into the panels and apertures of the article groups as described.

It will be recognised that as used herein, directional references such as “top”, “bottom”, “front”, “back”, “end”, “side”, “inner”, “outer”, “upper” and “lower” do not limit the respective panels to such orientation, but merely serve to distinguish these panels from one another.

As used herein, the terms “hinged connection” and “fold line” refer to all manner of lines that define hinge features of the blank, facilitate folding portions of the blank with respect to one another, or otherwise indicate optimal panel folding locations for the blank. A fold line is typically a scored line, an embossed line, or a debossed line. Any reference to hinged connection or fold line should not be construed as necessarily referring to a single fold line only; indeed it is envisaged that hinged connection can be formed from any one or more of the following, a short slit, a frangible line or a fold line without departing from the scope of the invention. 

1. A tool assembly for folding a blank to form a carrying handle, the tool assembly comprising: a first pair of fingers for gripping a blank and a second pair of fingers for gripping the blank, the fingers of the first pair of fingers being pivotally coupled with respect to one another, and the fingers of the second pair of fingers being pivotally coupled with respect to one another, the fingers of each of the first and second pairs of fingers being coupled to an actuator for movement between a receiving position and a gripping position wherein the fingers of the first and second pairs of fingers are configured to engage a blank in the receiving position and configured to fold said blank when disposed in the gripping position, at least one of the first and second pairs of fingers being rotationally mounted to a tool head and coupled to a drive mechanism for rotation with respect to the tool head, such that the tool assembly is configured to grip first and second portions of the blank and to fold the first portion of the blank with respect to the second portion of the blank.
 2. The tool assembly of claim 1 wherein the tool head is slidably mounted to a carriage for linear movement with respect to the carriage.
 3. The tool assembly of claim 2 wherein the carriage is mounted to a conveyor.
 4. A method of packaging groups of articles comprising: (i) forming a carrying handle from a blank, wherein the forming comprises folding a first portion of the blank about a longitudinally extending fold line, and holding the first portion in said folded condition whilst folding said first portion about a transverse fold line to be substantially perpendicular to a second portion; and (ii) inserting said first portion into an aperture or void disposed between four adjacent articles forming part of a group of articles, wherein the first portion comprises a first engaging edge for locking with a second engaging edge of the group of articles, the first engaging edge engaging with said second engaging edge by at least partially unfolding the first portion about the longitudinal fold line.
 5. The method of claim 4 comprising folding a third portion of the blank about a longitudinally extending fold line, holding the third portion in said folded condition whilst folding said third portion about a transverse fold line to be substantially perpendicular to the second portion and inserting said third portion into a second aperture or void defined by four adjacent articles in the group of articles and unfolding the third portion about said longitudinally extending fold line so as to engage an engaging edge of the third portion with an engaging edge of the group of articles thereby locking the third portion within the second aperture or void.
 6. The method of claim 4 wherein the entire blank is folded about a longitudinally extending fold line and wherein the second portion is unfolded into a substantially flat condition when the first and/or third portions are folded to be perpendicular to the second portion.
 7. A packaging machine for packaging a group of articles comprising: (i) a conveyor for providing a group of articles; (ii) a conveyor for providing a blank for forming a carrying handle; (iii) a tool assembly comprising a pair of fingers for folding a first portion of the blank about a longitudinally extending fold line; (iv) the fingers being pivotally mounted to a tool head of the tool assembly for folding the first portion of the blank to be substantially perpendicular to a second portion of the blank; (v) wherein the tool head is slideably mounted to a carriage for insertion of the first portion into an aperture or void in the group of articles.
 8. The packaging machine of claim 7 wherein the fingers grip the blank and hold the first portion of the blank in a folded condition when in a closed position.
 9. The packaging machine of claim 7 wherein the fingers hold the first portion of the blank in a folded condition whilst folding the first portion about a transverse fold line so as to be substantially perpendicular to the second portion.
 10. The packaging machine of claim 7 wherein the tool assembly comprises a second pair of fingers mounted to the tool head for folding a third portion of the blank about a longitudinally extending fold line, the fingers being pivotally mounted to the tool head for folding the first portion of the blank to be substantially perpendicular to the second portion, whilst the third portion is held in a folded condition about the longitudinally extending fold line.
 11. The packaging machine of claim 7 comprising a lug or mandrel mounted on a conveyor for engaging with the blank for facilitating folding of the blank about the longitudinal fold line.
 12. The packaging machine of claim 7 comprising at least one guide for insertion between a pair of articles in the group of articles, the at least one guide aligns the first portion or third portion of the blank during insertion into the group of articles and maintains the first or third portion in a folded condition.
 13. A packaging machine for packaging a group of articles comprising a guide for insertion between a pair of articles in the group of articles, the guide comprising a recess for receiving and maintaining a first portion of a carrying handle in a folded condition during insertion of the first portion of the carrying handle into the group of articles.
 14. (canceled)
 15. The method of claim 5 wherein the entire blank is folded about a longitudinally extending fold line and wherein the second portion is unfolded into a substantially flat condition when the first and/or third portions are folded to be perpendicular to the second portion.
 16. The packaging machine of claim 8 comprising at least one guide for insertion between a pair of articles in the group of articles, the at least one guide aligns the first portion or third portion of the blank during insertion into the group of articles and maintains the first or third portion in a folded condition.
 17. The packaging machine of claim 9 comprising at least one guide for insertion between a pair of articles in the group of articles, the at least one guide aligns the first portion or third portion of the blank during insertion into the group of articles and maintains the first or third portion in a folded condition.
 18. The packaging machine of claim 10 comprising at least one guide for insertion between a pair of articles in the group of articles, the at least one guide aligns the first portion or third portion of the blank during insertion into the group of articles and maintains the first or third portion in a folded condition.
 19. The packaging machine of claim 8 comprising a lug or mandrel mounted on a conveyor for engaging with the blank for facilitating folding of the blank about the longitudinal fold line.
 20. The packaging machine of claim 9 comprising a lug or mandrel mounted on a conveyor for engaging with the blank for facilitating folding of the blank about the longitudinal fold line.
 21. The packaging machine of claim 10 comprising a lug or mandrel mounted on a conveyor for engaging with the blank for facilitating folding of the blank about the longitudinal fold line. 